Dirty water distillation and salt harvesting system, method, and apparatus

ABSTRACT

Embodiments of the present disclosure can include a system for harvesting salt and generating distilled water from at least one of a produced water and salt water, comprising. A direct steam generator (DSG) can be configured to generate saturated steam and combustion exhaust constituents from the at least one of the produced water and salt water. A separation system can be configured to separate the salt from at least one of the saturated steam and combustion exhaust constituents in brine form or solid form. An expansion turbine can be configured to recover energy from the steam and combustion exhaust constituents.

FIELD OF THE INVENTION

Embodiments of the present disclosure relate generally to a method,apparatus and system for the cost-effective distillation of dirty waterand the parallel harvesting of salts and other valued inorganic product.The system, apparatus and method can be used in the enhanced oilrecovery industry in processes such as Hydraulic Fracturing, or anyother application which requires large quantities of distilled water andhas available brine or salt laden water.

BACKGROUND

The Hydraulic Fracturing hydrocarbon recovery process has proven to bean effective way of recovering fossil energy. It is not without negativeissues. One of the undesirable traits of the process is its need forlarge quantities of water in the beginning of the process. A typicalwell will require 3 million to 5 million gallons of water in thebeginning or injection part of a fracing process. Clean water ispreferred for this process. There is a larger disposal requirement todispense with fossil water or salt laden brine water which is returnedduring the balance of the hydrocarbon recovery process. This fossilwater is known as “produced water” and contains large amounts of salts.In some cases, over 200,000 ppm of salts. For every barrel of oilrecovered in a Fracing operation there is typically between 3 to 10barrels of produced water that needs to be disposed of. To date, thecurrent practice for produced water disposal is deep well injection. Theproduced water is effectively pumped deep into the ground.Unfortunately, it appears this process has precipitated seismic eventsor earth quakes in a number of locations. A better more effective methodof produced water disposal such as the one taught in this disclosure isneeded.

SUMMARY

Embodiments of the present disclosure can include a system forharvesting salt and generating distilled water from at least one of aproduced water and salt water, comprising. A direct steam generator(DSG) can be configured to generate saturated steam and combustionexhaust constituents from the at least one of the produced water andsalt water. A separation system can be configured to separate the saltfrom at least one of the saturated steam and combustion exhaustconstituents in brine form or solid form. An expansion turbine can beconfigured to recover energy from the steam and combustion exhaustconstituents.

Embodiments of the present disclosure can include a system forharvesting salt and generating distilled water from at least one of aproduced water and salt water. A direct steam generator (DSG) can beconfigured to generate saturated steam and combustion exhaustconstituents from the at least one of the produced water and salt water.A separation system can be configured to separate the salt from at leastone of the saturated steam and combustion exhaust constituents in brineform or solid form. An expansion turbine can be configured to recoverenergy from the steam and combustion exhaust constituents.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a simplified schematic representation of a dirty waterdistillation system, salt harvesting method, and apparatus, inaccordance with embodiments of the present disclosure.

FIG. 2 depicts a second schematic representation of a dirty waterdistillation system, salt harvesting method, and apparatus that includesa Rankine cycle generator system, in accordance with embodiments of thepresent disclosure.

FIG. 3 depicts a third schematic representation of a dirty waterdistillation system, salt harvesting method, and apparatus, inaccordance with embodiments of the present disclosure.

DETAILED DESCRIPTION

Embodiments of the present disclosure relate generally to a method,apparatus and system for the cost-effective distillation of dirty waterand parallel salt harvesting. The system, apparatus and method can beused in the enhanced oil recovery industry in processes such asHydraulic Fracturing, or any other application which requires largequantities of distilled water and has available brine or salt ladenwater.

FIG. 1 depicts a simplified schematic representation of a dirty waterdistillation system, salt harvesting method, and apparatus, inaccordance with embodiments of the present disclosure. In FIG. 1, dirtywater or salt laden produced water from fracing operations or other saltwater intensive processes enters the process in conduit 1. As depicted,the water can have a temperature of 70 degrees Fahrenheit (F), althoughthe temperature of the water can be less than or greater than 70 degreesF. The produced water can be heated in optional tank 2 with optionalheat exchanger 3. The heat energy can come from optional heat sources Aor B (e.g., heat sources 9 or 14). The pre-heated produced water inconduit 4 is brought to as high a temperature as possible withoutboiling. For standard conditions the produced water can be heated toapproximately 210 degrees F. Conduit 4 is in communication with a directsteam generator 5 as described in U.S. provisional patent applicationNo. 62/381,983, which is incorporated by reference as though fully setforth herein. The direct steam generator (DSG) 5 is configured tooperate on compressed oxidant, which can be provided via conduit 12 anda hydrocarbon fuel provided via conduit 11. In some embodiments, energyin an amount of approximately 29 megawatts can be introduced into theDSG, although the amount of energy can be greater than or less than 29megawatts. The hydrocarbon fuel can be flair gas also known as casinghead gas or it can be any other available fuel, such as natural gas. Theoxidant can be air or an oxygen enriched air from an enriched level ofoxygen in a range from 20% oxygen by volume to 100% oxygen by volume. Inembodiments of the present disclosure, non-enriched air can be used asthe oxidant. The air can be compressed to increase efficiency and heattransfer. The pressure of the air oxidant can be in a range from 30pounds per square inch absolute (psia) to 2,000 psia. A preferredpressure of the air oxidant can be in a range from 60 psia to 700 psia,and more specifically in a range from 60 psia to 280 psia. In anexample, and as depicted, the air oxidant can have a pressure ofapproximately 250 psia, although embodiments are not so limited. Theoxidant temperature of the oxidant flowing through conduit 12 should beas high as possible and can be in a range from 200 degrees F. to 1,000degrees F., in some embodiments. A preferred temperature of the oxidantflowing through conduit 12 can be in a range from 400 degrees F. to 600degrees F. The DSG can be operated in a steam generation condition whereblowdown is created in conduit 15 or cyclone exit 16, which wouldproduce a high concentration brine. A blowdown level can be from 2% to30% with a preferred range of 3% to 10%. The steam, DSG exhaust, andsolids in conduit 6 can also be created to contain from 100% qualitysteam to a superheated steam condition. Steam in this condition canprecipitate the salts from the feedwater as solids. The salt solids canbe separated from the steam in cyclone 7 and can flow out of the exitconduit 16. In an example of a 5,000 barrel per day system with 250,000ppm salt solids and other valued inorganic material, the system canharvest approximately 170 tons per day of salt and valued materialthrough exit conduit 16. This product has significant value and supportsthe economic viability of this process. Other valued inorganic materialtypically found in produced water can be lithium, silver, magnesium,aluminum and many other elements, which can be harvested via embodimentsof the present disclosure.

Steam energy in conduit 8 can be extracted in an optional heat recoverysystem 9, which can include a heat exchanger, for example. Optional ductfired burner 10 or other type of heat source can be used to optimizeenergy content in the system. For example, the duct fired burner 10 canadd heat energy to the steam and DSG exhaust traveling through conduit18. Fuel conduit 17 delivers fuel to the duct fired burner which can becasing head gas or any other available fuel.

The steam and DSG exhaust in conduit 18 are processed through expansionturbine 19 to turn shaft 20. Optional asynchronous or synchronousgenerator 21 can be used to generate electricity from the extractedenergy from expansion turbine 19. As depicted, the asynchronous orsynchronous generator 21 can produce approximately 1.1 MWe of energy,although examples are not so limited and a greater or lesser amount ofenergy can be produced by the generator 21. Compressor 22 is used tocompress DSG oxidant, which in this example is air. The air enters inconduit 26 and may be preheated with recovered energy from sources A orB in heat transfer system 13 (e.g., heat exchanger). In an example, andas depicted, the air can be at a temperature of 69 degrees F., althoughthe temperature of the air can be less than or greater than 69 degreesF. The energy transferred via heat transfer system 13 may be modulatedto control the DSG oxidant supply at a maximum desired temperature whenthe included heat of compression through compressor 22 is integrated. Inthis example 600 degrees F. is the desired control point for the inlettemperature of the oxidant supply to the DSG when the energy is summedfrom the ambient air, the energy recovered via heat transfer system 13and the heat of compression generated from the compressor 22. However,embodiments are not so limited and the inlet temperature of the oxidantsupply to the DSG can be less than or greater than 600 degrees F., asfurther discussed herein.

The remaining stored energy in conduit 23 from the expansion turbine 19may be recovered in heat exchanger 14 which is denoted as heat source B.An optional condenser 24 with its cooling towers 25 may be used to fullycondense the steam in conduit 33 to form distilled water which wouldexit conduit 27.

FIG. 2 depicts a second schematic representation of a dirty waterdistillation system, salt harvesting method, and apparatus that includesa Rankine cycle generator system, in accordance with embodiments of thepresent disclosure. FIG. 2 shows the same basic system as depicted inFIG. 1 with the same basic elements, as denoted by a “prime” symbolindicating the same basic elements. For example, the DSG 5 can be thesame or similar to the DSG 5′. In some embodiments, the system caninclude the addition of an optional Rankine cycle generator system or anoptional Organic Rankine cycle generation system 29. For example, FIG. 2includes the same or similar features as FIG. 1, as denoted by thereference numerals, with the exception that FIG. 2 depicts the additionof an optional Rankine cycle generator system or the optional OrganicRankine cycle generation system 29. The optional Rankine cycle generatorsystem or the optional Organic Rankine cycle generator system 29 can befed energy in the form of DSG exhaust, steam and/or steam condensatefrom conduit 33′ and/or conduit 28. For example, DSG exhaust, steamand/or steam condensate can be provided to the optional Rankine cyclegenerator system or the optional Organic Rankine cycle generator system29 solely via conduit 33′ or conduit 28 or provided via conduits 33′ and28 combined. In some embodiments, electricity 30 can be generated viathe optional Rankine cycle generator system or the optional OrganicRankine cycle generator system 29.

In FIG. 2, dirty water or salt laden produced water from fracingoperations or other salt water intensive processes enters the process inconduit 1′. As depicted, the water can have a temperature of 70 degreesFahrenheit (F), although the temperature of the water can be less thanor greater than 70 degrees F. The produced water can be heated inoptional tank 2′ with optional heat exchanger 3′.

The heat energy can come from optional heat sources A or B (e.g., heatsources 9′ or 14′). The pre-heated produced water in conduit 4′ isbrought to as high a temperature as possible without boiling. Forstandard conditions the produced water can be heated to approximately210 degrees F. Conduit 4′ is in communication with a direct steamgenerator 5′ as previously described. The direct steam generator (DSG)5′ is configured to operate on compressed oxidant, which can be providedvia conduit 12′ and a hydrocarbon fuel provided via conduit 11′. In someembodiments, energy in an amount of approximately 29 megawatts can beintroduced into the DSG, although the amount of energy can be greaterthan or less than 29 megawatts. The hydrocarbon fuel can be flair gasalso known as casing head gas or it can be any other available fuel,such as natural gas. The oxidant can be air or an oxygen enriched airfrom an enriched level of oxygen in a range from 20% oxygen by volume to100% oxygen by volume. In embodiments of the present disclosure,non-enriched air can be used as the oxidant. The air can be compressedto increase efficiency and heat transfer. The pressure of the airoxidant can be in a range from 30 pounds per square inch absolute (psia)to 2,000 psia. A preferred pressure of the air oxidant can be in a rangefrom 60 psia to 700 psia, and more specifically in a range from 60 psiato 280 psia. In an example, and as depicted, the air oxidant can have apressure of approximately 250 psia, although embodiments are not solimited. The oxidant temperature of the oxidant flowing through conduit12′ should be as high as possible and can be in a range from 200 degreesF. to 1,000 degrees F., in some embodiments. A preferred temperature ofthe oxidant flowing through conduit 12′ can be in a range from 400degrees F. to 600 degrees F. The DSG can be operated in a steamgeneration condition where blowdown is created in conduit 15′ or cycloneexit 16′, which would produce a high concentration brine. A blowdownlevel can be from 2% to 30% with a preferred range of 3% to 10%. Thesteam, DSG exhaust, and solids in conduit 6′ can also be created tocontain from 100% quality steam to a superheated steam condition. Steamin this condition can precipitate the salts from the feedwater assolids. The salt solids can be separated from the steam in cyclone 7′and can flow out of the exit conduit 16′. In an example of a 5,000barrel per day system with 250,000 ppm salt solids and other valuedinorganic material, the system can harvest approximately 170 tons perday of salt and valued material through exit conduit 16′. This producthas significant value and supports the economic viability of thisprocess. Other valued inorganic material typically found in producedwater can be lithium, silver, magnesium, aluminum and many otherelements.

Steam energy in conduit 8′ can be extracted in an optional heat recoverysystem 9′, which can include a heat exchanger, for example. Optionalduct fired burner 10′ or other type of heat source can be used tooptimize energy content in the system. For example, the duct firedburner 10′ can add heat energy to the steam and DSG exhaust travelingthrough conduit 18′. Fuel conduit 17′ delivers fuel to the duct firedburner which can be casing head gas or any other available fuel.

The steam and DSG exhaust in conduit 18′ are processed through expansionturbine 19′ to turn shaft 20′. Optional asynchronous or synchronousgenerator 21′ can be used to generate electricity from the extractedenergy from expansion turbine 19′. As depicted, the asynchronous orsynchronous generator 21′ can produce approximately 1.1 MWe of energy,although examples are not so limited and a greater or lesser amount ofenergy can be produced by the generator 21′. Compressor 22′ is used tocompress DSG oxidant, which in this example is air. The air enters inconduit 26′ and may be preheated with recovered energy from sources A orB in heat transfer system 13′ (e.g., heat exchanger). In an example, andas depicted, the air can be at a temperature of 69 degrees F., althoughthe temperature of the air can be less than or greater than 69 degreesF. The energy transferred via heat transfer system 13′ may be modulatedto control the DSG oxidant supply at a maximum desired temperature whenthe included heat of compression through compressor 22′ is integrated.In this example 600 degrees F. is the desired control point for theinlet temperature of the oxidant supply to the DSG when the energy issummed from the ambient air, the energy recovered via heat transfersystem 13′ and the heat of compression generated from the compressor22′. However, embodiments are not so limited and the inlet temperatureof the oxidant supply to the DSG can be less than or greater than 600degrees F., as further discussed herein.

The remaining stored energy in conduit 23′ from the expansion turbine19′ may be recovered in heat exchanger 14′ which is denoted as heatsource B. As previously discussed, the optional Rankine cycle generatorsystem or the optional Organic Rankine cycle generator system 29 can befed energy in the form of DSG exhaust, steam and/or steam condensatefrom conduit 33′ and/or conduit 28. For example, DSG exhaust, steamand/or steam condensate can be provided to the optional Rankine cyclegenerator system or the optional Organic Rankine cycle generator system29 solely via conduit 33′ or conduit 28 or provided via conduits 33′ and28 combined. In some embodiments, electricity 30 can be generated viathe optional Rankine cycle generator system or the optional OrganicRankine cycle generator system 29.

FIG. 3 is a simplified system that communicates the DSG exhaust andsteam directly with a condenser 24″ to make distilled water in conduit27″ and generates compressed oxidant in conduit 12″ for the DSG by usinga shaft driven blower or compressor 31″. For example, FIG. 3 includesthe same or similar features as FIG. 1, as denoted by the referencenumerals, which include “primes” to denote similarities, with theexception that the system in FIG. 3 communicates the DSG exhaust andsteam directly with a condenser 24″ to make distilled water in conduit27″ and generates compressed oxidant in conduit 12″ for the DSG by usinga shaft driven blower or compressor 31″. The power to turn the shaft 32″can be generated from an electric motor driven by a casing head fueledor other hydrocarbon fuel sourced internal combustion generator orBrayton cycle generator. The shaft 32″ can also be powered directly byan internal combustion engine or Brayton cycle turbine operating on anyfuel such as natural gas, diesel or casing head gas.

As further depicted, an oxidant can be provided via conduit 11″ to theDSG 5″, as previously discussed with respect to FIG. 1. In someembodiments, water can be provided to the DSG 5″ via the water conduit4″ and salt and/or solids can be precipitated from the steam produced bythe DSG 5″ in the cyclone 7″ and can flow out of the exit conduit 16″.Steam energy in conduit 8″ can flow into the condenser 24″, as discussedabove. In some embodiments, the condenser 24″ can be fluidly/thermallycoupled with a cooling tower 25″.

Embodiments are described herein of various apparatuses, systems, and/ormethods. Numerous specific details are set forth to provide a thoroughunderstanding of the overall structure, function, manufacture, and useof the embodiments as described in the specification and illustrated inthe accompanying drawings. It will be understood by those skilled in theart, however, that the embodiments may be practiced without suchspecific details. In other instances, well-known operations, components,and elements have not been described in detail so as not to obscure theembodiments described in the specification. Those of ordinary skill inthe art will understand that the embodiments described and illustratedherein are non-limiting examples, and thus it can be appreciated thatthe specific structural and functional details disclosed herein may berepresentative and do not necessarily limit the endoscope of theembodiments, the endoscope of which is defined solely by the appendedclaims.

Reference throughout the specification to “various embodiments,” “someembodiments,” “one embodiment,” or “an embodiment”, or the like, meansthat a particular feature, structure, or characteristic described inconnection with the embodiment(s) is included in at least oneembodiment. Thus, appearances of the phrases “in various embodiments,”“in some embodiments,” “in one embodiment,” or “in an embodiment,” orthe like, in places throughout the specification, are not necessarilyall referring to the same embodiment. Furthermore, the particularfeatures, structures, or characteristics may be combined in any suitablemanner in one or more embodiments. Thus, the particular features,structures, or characteristics illustrated or described in connectionwith one embodiment may be combined, in whole or in part, with thefeatures, structures, or characteristics of one or more otherembodiments without limitation given that such combination is notillogical or non-functional.

Although at least one embodiment for a dirty water distillation and saltharvesting system, method, and apparatus has been described above with acertain degree of particularity, those skilled in the art could makenumerous alterations to the disclosed embodiments without departing fromthe spirit or scope of this disclosure. Additional aspects of thepresent disclosure will be apparent upon review of Appendix A1. Alldirectional references (e.g., upper, lower, upward, downward, left,right, leftward, rightward, top, bottom, above, below, vertical,horizontal, clockwise, and counterclockwise) are only used foridentification purposes to aid the reader's understanding of the presentdisclosure, and do not create limitations, particularly as to theposition, orientation, or use of the devices. Joinder references (e.g.,affixed, attached, coupled, connected, and the like) are to be construedbroadly and can include intermediate members between a connection ofelements and relative movement between elements. As such, joinderreferences do not necessarily infer that two elements are directlyconnected and in fixed relationship to each other. It is intended thatall matter contained in the above description or shown in theaccompanying drawings shall be interpreted as illustrative only and notlimiting. Changes in detail or structure can be made without departingfrom the spirit of the disclosure as defined in the appended claims.

Any patent, publication, or other disclosure material, in whole or inpart, that is said to be incorporated by reference herein isincorporated herein only to the extent that the incorporated materialsdoes not conflict with existing definitions, statements, or otherdisclosure material set forth in this disclosure. As such, and to theextent necessary, the disclosure as explicitly set forth hereinsupersedes any conflicting material incorporated herein by reference.Any material, or portion thereof, that is said to be incorporated byreference herein, but which conflicts with existing definitions,statements, or other disclosure material set forth herein will only beincorporated to the extent that no conflict arises between thatincorporated material and the existing disclosure material.

1. A system for harvesting salt, and other valued inorganic material,and generating distilled water from at least one of a produced water andsalt water, comprising: a direct steam generator (DSG) configured togenerate saturated steam and combustion exhaust constituents from the atleast one of the produced water and salt water; a separation systemconfigured to separate the salt from at least one of the saturated steamand combustion exhaust constituents in brine form or solid form; and anexpansion turbine configured to recover energy from the steam andcombustion exhaust constituents.
 2. A system for harvesting salt, andother valued inorganic material, and generating distilled water from atleast one of produced water and salt water, comprising: a direct steamgenerator (DSG) configured to generate at least one of saturated steamand superheated steam and combustion exhaust constituents from the leastone of produced water and salt water; a separation system configured toseparate the salt from the at least one of the saturated steam andsuperheated steam and combustion exhaust constituents in brine form orsolid form; and an expansion turbine configured to recover energy fromthe steam and combustion exhaust constituents.
 3. The system as in anyone of claims 1 and 2, wherein an oxidant for the DSG includes pure air.4. The system as in any one of claims 1 and 2, wherein an oxidant forthe DSG includes oxygen enriched air that is enriched with up to 100%oxygen by volume.
 5. The system as in any one of claims 1 and 2, whereina fuel for the DSG includes casing head gas.
 6. The system as in any oneof claims 1 and 2, wherein the expansion turbine provides energy for anelectrical generator.
 7. The system as in any one of claims 1 and 2,wherein the expansion turbine is configured to provide energy for anoxidant compressor, the oxidant compressor configured to provide anoxidant to the DSG.
 8. The system as in any one of claims 1 and 2,wherein the expansion turbine is configured to provide energy for anelectrical generator and at least one of an oxidant compressor andblower.
 9. The system of claim 8, wherein at least one of the oxidantcompressor and blower is powered by at least one of an electric motor,Brayton cycle turbine, and an internal combustion engine.
 10. The systemof claim 9, wherein at least one of the Brayton cycle turbine and theinternal combustion engine is powered by casing head gas.
 11. The systemof claim 8, wherein the electricity to power at least one of the oxidantcompressor and blower is generated by at least one of a Brayton cyclegenerator and an internal combustion generator fueled by natural gas orcasing head gas.
 12. The system as in any one of claims 1 and 2, whereina duct fired burner is used to trim the required energy in the system.13. The system of claim 12, wherein the duct fired burner is fueled bycasing head gas.
 14. The system as in any one of claims 1 and 2, whereinheat recovery from the steam is used to maintain an elevated temperaturein a feedwater that includes the at least one of the produced water andsalt water and an oxidant provided to the DSG.
 15. The system as in anyone of claims 1 and 2, further comprising a Rankine cycle generator thatis used to generate electricity from the steam generated by the DSG. 16.The system as in any one of claims 1 and 2, wherein an organic Rankinecycle generator is used to generate electricity from the steam generatedby the DSG.